NORD Australia director Max Jarmatz speaks with ABHR to learn more about the gearboxes that are powering one of Europe’s longest overland conveyors.
The Bucim copper mine is one of the only operating copper mines in North Macedonia.
Ore was discovered pre-World War II, with active exploration beginning in 1979. Soon, the site featured an open pit copper and gold mine, along with a floatation mill.
Here, 4.5 million tonnes of highly sought after ore is processed annually.
Within the Bucim project is the Borov Dol mine, which aims to extend the life of Bucim’s operations to at least 2030.
As part of this project, a 6.3km overland conveyor belt was constructed to connect the historic production site with the new mine.
At the beating heart of this conveyor are three NORD Drivesystems 400kW industrial gearboxes.
NORD Australia director Max Jarmatz told ABHR that the company’s equipment plays a critical role in ensuring the proper output torque is delivered to power long overland conveyor belts.
“Without robust, efficient gearboxes, conveyor systems risk unplanned downtime, increased costs, and decreased productivity,” he said.
“Motors typically produce lower torque with higher speeds determined by the electric grid’s frequency. Frequency inverters can modify motor speed, or larger motors can generate more torque.
“However, the most economical method uses a lever effect in gearboxes, which reduces speed mechanically while increasing torque. We’ve perfected this over nearly 60 years with solutions provided to over 100 industries.”
With production facilities in 36 countries, NORD has been assembling its high-quality drive solutions in Australia since 2008.
NORD’s gear units are manufactured with the UNICASE design, developed in-house in the 1980s to endure harsh industrial conditions. The UNICASE housing, machined from a single piece, integrates all transmission elements and heavy-duty bearings. This design is a hallmark of NORD’s MAXXDRIVE industrial gear units, which offer high output torques from 15,000 to 282,000 Newton metres, with power inputs between 1.5 and 2000 kilowatts.
The MAXXDRIVE range is specifically engineered for heavy-duty applications like conveyor belt drives, making it ideal for industries requiring high input powers across wide-speed ranges.
Because the Borov Dol mine is located in a complex ecosystem, with the conveyor crossing a major road, making sure the equipment is reliable was vital.
Fast-moving conveyors generate significant thermal energy, leading to thermal losses. To mitigate this, NORD developed the highly efficient MAXXDRIVE XT industrial gear unit equipped with fins that radiate more heat and reduce the risk of thermal overload. Additionally, the XT design requires a lower oil level. This allows conveyors to operate faster and handle higher loads without overheating or requiring external cooling systems.
Jarmatz said quality aftersales support is vital when it comes to major projects like Borov Dol.
“For critical projects, we engage local service providers with the necessary personnel and tools close to our customer, while NORD provides expertise, drawings, and spare parts,” he said.
NORD can also equip gearboxes with pre-installed sensors for integration into SCADA systems, enabling predictive maintenance through monitoring of vibration, temperature, and other critical parameters.
The MAXXDRIVE gear units are available as helical or bevel gear units, with various output shaft and flange options for optimal application connections. With additional options for harsh environments, MAXXDRIVE units – in particular – are designed to withstand fluctuating ambient conditions. TACONITE seals, heavy-duty bearings and NSD5 paint specs guarantee a long service life.
Over the past decade, NORD has developed three new motor generations driven by European government standards. NORD IE3 motors are up to 94 per cent efficient. NORD’s gearboxes utilise highly efficient bevel and inline gears, achieving 96 per cent efficiency per stage, minimising thermal losses, and reducing a mine’s carbon footprint.
“Our gearboxes often come as part of a base frame arrangement with a motor and additional components like couplings, brakes, or IoT sensors,” Jarmatz said.
“Each NORD industrial gearbox project is like a mini engineering project, as we strive to meet all customer specifications and requirements.”
In recent years, NORD has expanded its customer base in traditional mining sectors such as iron ore and copper while also delivering innovative solutions for the rapidly growing lithium ore market.
To further support Australian industries, NORD operates a gearbox assembly facility in Melbourne, Victoria, and offers an Australia-wide service partner network for repairs, spare parts, and after-sales support.
“We take pride in supplying highly efficient gearboxes to the lithium industry, fuelling the demand for electric vehicles worldwide. This collaboration is a perfect match, combining German engineering with Australian entrepreneurship,” Jarmatz said.